Sealed-in regulator



May 29, 1945. w J Y 2,377,265

SEALED-IN REGULATOR Filed Jan. 9, 1942 1/1/17/119172 HEB V HIS ATTORNEYE Patented May 29, 1945 2,311,205 SEALED-IN REGULATOR;

William J. Rady, Anderson, Ind., aaaignor to General Motor. Corporation,Detroit, Micln, a corporation of Delaware Application January 9, 1942,Serial No. 426,154

"IClaims.

This invention relates to apparatus for controlling the circuit betweenthe storage battery and the generator and for regulating the generator.The circuit connections are controlled by the reverse current relaywhich closes when the generator voltage exceeds the battery volt-' age'and disconnects the generator from the battery when the generatorvoltage falls below the battery voltage. The generator is regulated by avoltage regulator, or by a voltage regulator and a current regulator.

An object of the invention is to provide for the economical manufactureof sealed regulator units filled with inert gas in order to protect thecontacts of the regulators from oxidation. To accomplish this, I providethe regulator units with a base comprising an insulating disc formedfrom a sheet of hard insulating material and apertured for receiving andcorrectly spacing the terminal members, plug or threaded studs, as thecase may be. Upon the insulating disc is located a metal plate of largerdiameter and apertured, providing holes which will clear the terminalmembers projecting through them. Upon the metal disc is located a softrubber disc having apertures through which the terminal extends. Thesoft rubber disc is vulcanized to the metal disc and to the terminals soas to insulate the terminals. Upon the rubber disc is located aninsulating disc to which the regulator magnet and contact assembly areattached. The insulating disc is apertured to receive the upper ends ofthe terminals which are riveted over against the disc thereby clampingthe four discs against shoulders provided by each of the terminals andbearing against the first-mentioned insulating disc. The regulatormagnet and contact assembly is enclosed by a cup-shaped housing havingan annular flange so formed as to provide a shoulder against which theinner surface of the rubber disc bears when the base and the housing areassembled. The outer edge of the annular flange of the housing is forcedagainst the peripheral portion of the metal disc thereby placing theperipheral portion of the soft rubber disc under compression. The edgeof the flange is soldered to the metal disc to provide an effective sealbetween the base and the housing. The flat face of the housing isprovided with a short tubular extension adapted to be attached to a pipeconnected with a vacuum pump, for withdrawing air from the housing, andthen connected with a supply of inert gas. After evacuating and fillingand then evacuating and filling the second time, the housing of theextension is pinched together and sealed by soldering. This matter ofsealing the housing of the regulator is found to be effective inretaining an inert gas under atmospheric pressure and even underpressure substantially greater than atmospheric for an indefiniteperiod.

Further objects and advantages of the present invention will be apparentfrom the following description, reference being had to the accompanyingdrawing wherein preferred embodiments of the present invention areclearly shown.

' In the drawing:

- Fig. 1 is a plan view of the voltage regulator unit embodying thepresent invention but with the cup-shaped housing omitted;

Fig. 2 is a side view with the cup-shaped housing in section beforesealing the tubular extension thereof v Fig. 3 is a sectional view takenalong the line 3-4 of Fig. 1;

Fig. 4 is a fragmentary sectional view showing one of the plug terminalsconnected with a socket member on the mounting base;

Fig. 5 is a plan view of a current regulator embodying the presentinvention, the cup-shaped housing being omitted;

Fig. 6 is a side view thereof with the housing shown in section andafter the tubular housing extension is sealed;

Fig. 7 is a fragmentary sectional view showing the connection of athreaded terminal stud member of the unit with a conductor carried bythe mounting bracket;

The voltage regulator will first be described with reference to Figs 1to 4. The base of this regulator comprises a non-conducting plate 20(Fig. 3) formed from a sheet of hard insulating material and providedwith apertures for receiving three plug terminals 2i, 22 and 23 locatedas shown in Fig. 1. The upper portion of these terminals, such as 23aFig. 4, fits snugly within openings in plate 20. Next to the plate 20 islocated a metal disc 24 having holes spaced according to the spacingshown in Fig. 1, but of larger diameter than the plugs 2| to 23. Disc 24is greater in diameter than the disc 20. A compressible body or disc 25is vulcanized to the metal disc 24 and to the plugs 2| to 23, which passthrough the disc 25. The disc 25 is preferably made of soft non-porousrubber. Next to the disc 25 is located an insulating disc 28 of hardmaterial upon which is secured a regulator magnet and contact assemblyto be described. The disc 26 is smaller in diameter than the rubber disc25. After attaching this assembly to the disc 28, it is placed upon theassembly of discs 2|, 24 and 25, and plug! 25 to 22-pass throughapertures provided by the disc 25. The upper end of the plugs areriveted'over,

as indicated, for example, at 22b (Fig. 4), thereby forcing all of thediscs 25, 24, 25 and 25 downwardly against shoulders provided by theplugs, for example, the shoulder 220 (Fig. 4). This causes some of thematerial of soft rubber disc 25 to be forced in the holes in the disc 24surrounding the plugs. The riveting over of the plug upper ends, as at2212, and the vulcanization of disc 25 to the plug terminals and to themetal disc 24 contribute to provide an eifective seal between the disc25 and the plugs extending therethrough.

As shown in Fig. 3, the regulator magnet and contact assembly comprisesan L-shaped magnetizable bracket 25 which is apertured at 2| to receivea reduced lower end 22 of a magnet core 22 extending through a magnetwinding 34 and a bracket 35 and having a head pole piece 25. The portion22 passes along through the disc 25 and is riveted over at 220 therebysecuring the disc 28 to the bracket 25. The bracket 25 is provided witha squirt 21 received by a hole in the disc 25 to prevent the bracket IIfrom turning relative to the disc 25. The upper end of bracket 30 isbifurcated to provide a pair of cars 40 each of which is attached by arivet 4| to the bifurcations of leaf spring blades or members 42 and 43which are located between an armature 44 and a rigid plate 45, theseparts being fastened together by rivets 46. The magnetic path of theregulator is provided by the core 25 to bracket 30 and the armature 44.The spring blades 42 and 48 may be made of dissimilar metals so as toprovide for a change in the air gap between the armature 44 and the pole25 in order to compensate for the variations in the current flow throughthe windings 24 due to changes in temperature. To facilitate this actthe bifurcations of the spring blade 42 are provided with humps 41, asshown in Figs. 1 and 2.

The blade 43 has its free end inclined upwardly away from the armature44 and carries a contact 50 having a spherical face for engaging a flatface of a contact'5l carried by a resilient arm 52 of a bracket 53insulatingly supported by the arm 35a of bracket 25 and attached theretoby a screw 54. The contact 55 is urged into engagement with contact by acoil spring 55 connected with a hook 56 of the plate 42 and with a hook51 of a bracket 55 attached to bracket 25 by rivets 59 integral withbracket 55. The action of spring 55 is such as to cause the arm 52 tobend upwardly after its contact 5| has been engaged by the contact 50.Therefore, there is a wiping action between the contacts 50 and 5|before they are separated and there is a wiping action after they arebrought together. This wiping action assists in keeping the contactsurfaces in good condition.

The regulator is enclosed by the base and by a cup-shaped housing Bilhaving its peripheral edge so shaped as to provide a shoulder at II forreceiving the upper surface of the rubber disc 25 and to provide anannular portion which fits snugly against the edge of the rubber disc 25and having a portion 65 formed against the outer surface of the metaldisc 24 with such pressure as to cause the peripheral portion of therubber disc 25 to 'be squeezed against the shoulder 5| and the annularportion 52 of the housing 60. The flange 63 is soldered to the metaldisc 24 as indicated at Ma. Thus an effective seal is provided betweenthe base 24 and the housing II.

The flat side of the housing 55 is provided with a tubular neck 55adapted to be engaged by a suitable fitting 552: connected by a pipehaving'a valve (not shown) by which the pipe may be placed incommunication either with a vaccum pump or with a source of the inertgas under pressure. The housing ll is first evacuated and then is filledwith the gas. such as nitrogen, for example. The nitrogen is withdrawntaking with it a greater portion of air which may have been left withinhousing after the first evacuation. Then the housing is filled againwith nitrogen and the housing is sealed by pinching together theextension 05, and soldered as shown in Fig. 6. Obviously severalevacuations and filling with nitrogen may take place before sealing, inorder to eliminate as much air as possible. This matter of sealing thehousing has been found to be very effective since nitrogen may bemaintained under pressure substantially greater than atmospheric withoutany appreciable diminution of the pressure for an indefinite period. Itis believed that this sealing i effective in maintaining the inert gasin the housing and excluding air over the period equal to the life ofthe instrument.

The winding 24 of the voltage regulator comprises a generator voltageresponsive coil and a field current carrying coil. (h e end of generatorvoltage responsive coil is connected with core 22, the other end with awire 55 which is connected with the terminal 22 (Fig. 1). The fieldcurrent carrying coil is connected by wire 57 (Fig. 2) with bracket 52carrying contact II. The other end of the coil is connected by wire 58(Fig. 1) with plugs 2|. The frame II is connected by short lead 52 (I"ig. 2) with plug 22. The above connections are all made before thehousing 55 is attached to the base.

Thus, I have provided a voltage regulator which is hermetically sealedin a gas filled chamber. I designate this regulator in its entirety bynumeral II.

The current regulator designated in its entirety by numeral 25 is likethe voltage regulator II in many respects. Where the parts of thecurrent regulator are exactly like those of the volta e regulatorsimilar reference numeral have been used to designate the similar parts.The current regulator differs from the voltage regulator in that thecore 23 is surrounded by one magnet coil 54 of relatively coarse wireshaving its ends connected with terminal clips 54a and 24b con nectedrespectively with threaded terminal studs 55 and 55. As shown in Fig. 7stud 55 provides a shoulder 26a bearing against the underside of thedisc 25. The upper end of stud I5 is riveted over at "b against the clip24b having an ear 54c projecting into a hole in the disc 25 in order toprevent the tuning of clip 84b. The clip 24a is secured to the stud 55in a similar manner. Plug 52 performs the fimction oi' plug 22 ofvoltage regulator II. That is, plug 23 is connected by a wire "a (Fig.6) with frame 30. Plug II is directly connected by wire lid with bracket52 which carries contact 5|.

The contacts of either regulator control the opening and closing of ashort-circuit around a resistance unit in the field circuit of thegenerator to be controlled. The resistance unit is not shown but it willbe understood that it is mounted upon the base or instrument board uponwhich the regulator is mounted. the base providing the sockets whichreceive the terminal plugs of the the second mentioned plate to hold themembers regulator. Such bases are disclosed in my copending applicationSerial No. 435,560, flied March 20, 1,942, which became Patent No.2,348,- 263 on May 9, 1944.

While the embodiment of the present invention as herein disclosed,constitutes a preferred form, it is to be understood that other formsmight be adopted, all coming within the scope of the claims which followWhat is claimed is as follows;

1. A sealed regulator enclosure for a vibrator and an inert gas forprotecting the contacts,

shanks extending through the aligned openings,

said shanks having securing portions bent over in assembled relation andalso the compressed areas of the body so that it will flow firmlyagainst the shank and into the spaces between the shank and marginalwalls of the openings in the metallic member to provide a fluid sealtherebetween; electrical connections between the vibrator and the plugs;a metallic cup-shaped housing for enclosing the vibrator and the base,the mouth of the housing being so shaped to provide a shoulder and aflange, said flange surrounding the peripheral edges of the metallicdisc and the bodv of resilient material; and mean including a part ofthe flange cooperating with the bottom side of the metallic disc forsecuring the base to the housing and also for compressing the resilientbody between the shoulder of the housing and the disc whereby theperipheral edge of the body is squeezed against the flange of thehousing to provide an eilective fluid seal between the base and thehousing.

2. A sealed regulator enclosure for a vibrator and an inert gas forprotecting the contacts, said enclosure comprising in combination a baseincluding an outer disc of non-conducting material having spacedopenings for receiving terminals; a metal disc overlying the first discand apertured to receive shanks of the terminals; a nonporous rubberdisc bonded to the metal plate and the shanks to provide a fluid sealtherebetween; an inner disc of non-conducting material supporting thevibrator and having openings through which the upper ends of the shanksextend, said shanks being riveted over the inner disc to clamp the discsagainst collars provided by terminals and engaging the outer disc; ametal cup-shaped housing enclosing the vibrator and base, the open endof the housing having an annular flange so formed to provide a shoulderagainst which the rubber disc bears; and means including a part ofthe'flange cooperating with the metal disc for securing the base to thehousing and thereby placing the peripheral portion of the rubber discunder compression to cause it to seal eilectively the joints between thebase and housing.

3. A sealed regulator enclosure for a vibrator and an inert gas forprotecting the contacts, said enclosure comprising in combination a baseincluding a metal plate apertured to receive shanks of the terminals butclear of metal plate; a soft body of resilient material vulcanized toone sideof the plate and having openings to receive the upper portionsof the shanks of terminals extending above said side of the plate; aplate of non-conducting material supporting the vibrator and resting onthe soft body, said non-conducting plate having openings through whichthe upper ends of the shanks extend, said upper ends of the shanks beingdeformed over the non-conducting plate to hold the metallic plate, ofsoft resilient material body and non-metallic plate in assembledrelation to provide the base and also causing the resilient materialtofill the space between the terminal shanks and the metal plate toprovide a fluid seal thereat; a metallic cupshaped housing enclosing thevibrator and base, the open end of the housing having a peripheralflange complementary to the contour of the metallic plate and so formedto provide a shoulder against which the body of resilient materialbears; means including a part of the flange c0- operating with the underside of the metallic plate for securing the base to the housing andthereby placing the peripheral portion of the resilient body undercompression to cause it to engage firmly the flange of the housing; andmeans for providing an effective seal between the base and housingcomprising a fusible material disposed between the bent over portion ofthe flange 'nd the metallic plate.

4. An electrical device of the type comprising a metallic cup-shapedcontainer having an internal shoulder at its open end, an operating unittherein including a fluid ingredient, said unit including an insulatingbase having spaced openings and means for attaching the unit to thebase, the combination therewith, of a composite closure for thecontainer including an insulating disc, a metallic disc and a softrubber disc, each disc having openings in alignment with the openings ofthe base with the openings of the metal disc being larger in crossdimensions; terminals extending through the openings, said terminalsbeing provided with shoulders against which the insulating disc rests;means including portions of the terminals cooperable with the base forclamping the discs and base together and for compressing the rubber disccausing portions thereof to flll the space between the metal disc andterminals to form a fluid tight seal thereat; electrical connectionsbetween the unit and terminals; and means for securing the closure tothe container, said means compressing the periphery of the rubber discagainst the shoulder for providing a fluid tight seal thereat.

5. A sealed enclosure for a vibrator and an inert gas for protecting thecontacts of the vibrator comprising the combination of an insulatingdisc supporting the vibrator; a metal disc and a nonporous rubber discvulcanized to the metal disc and disposed below the insulating disc; asecond insulating disc disposed below the metal disc, said discs havingaligned openings with the opening in the metal disc larger in dimensionsthan the other openings; terminal spective shoulders against which thediscs rest; means unitary with the terminals cooperating with the firstmentioned disc for clamping the discs against the shoulders and alsocompressin the rubber disc causing portions of the rubb'er disc to beforced into the enlarged opening of the metal disc to provide aneffective fluid seal between the rubber disc and the terminals;elecmembers passing through the openings, said terminals having retricaiconnections between the terminal members and the vibrator; a metalliccup-shaped housing for enclosing the vibrator, said housing having aperipheral ledge against which the peripheral edge of the rubber disccontacts; and means for securing the discs to the casing, said meanscomprising a flange exterior of the ledge and turned inwardly againstthe bottom face of the metal disc for compressing the peripheral edge ofthe rubber, disc between the metal disc and ledge to provide a fluidseal thereat; and fusible means for joining the flange to the metal discto provide a second fluid seal.

6. A sealed enclosure for an electrical device and an inert gas forprotecting the contacts of the device, said enclosure comprising incombination; a hollow metallic member having an opening and having aninternal shoulder near the opening; a base assembly including a metalmember and a non-porous yieldable member, said base assembly serving asa support for the device; means including portions of the hollow memberfor urging the base assembly inwardly to close the opening and forcompressing the non-porous yieldable member against the shoulder, saidhollow member being fluid-sealed internally at the shoulder; and fusiblemeans joining the metal member of the base assembly to the hollow memberto provide a metal seal ex- 30 gas leakage between the base assembly andthe hollow member.

7. A sealed enclosure tor a circuit breaker and an inert gas forprotecting the contacts thereof. said enclosure comprising incombination; a base including a member of non-conducting material forsupporting the circuit breaker; a metallic plate member; a non-porousbody 01' yieldable composition disposed between the members, saidmembers and body having aligned openings; a plurality of terminalselectrically connected with the circuit breaker and extending throughthe openings, said openings in the body adapted for snug encirclement ofa portion oi the terminals: means for holding the members and body inassembled relation and enforcing the body in sealing contact with theterminals; a metallic hollow member provided with an opening and havingan internal shoulder against which the periphery of the body ofyieldable composition bears; means including portions of the hollowmember engaging the exterior of the metal plate to secure the base tothe hollow member and for compressing the periphery of the yieldablebody with sealing contact with the shoulder; and fusible means joiningthe securing means of the hollow member to the metal plate to provide analloy seal between the metal plate and the hollow member and therebyprovide a plurality of barriers against inert gas leakage from theinterior of the hollow member.

WILLIAM J. RADY.

